Frame corner construction

ABSTRACT

There is provided an improved corner construction for interconnecting construction or frame members of a wall system. The corner construction is particularly useful with, but not limited to, a door structure of the type wherein a frame supports a panel of glass or other suitable material. The frame is formed of vertical frame members each having face portions connected by a transverse web and defining confronting glazing pockets. Spaced upper and lower rail members interconnect the vertical members and are each provided with longitudinally extending screw splines. The ends of the upper and lower rail members are coped to define tenons so that the screw splines fit within the confronting glazing pockets. Fastener means extending through the transverse webs into the screw splines expand the tenons to provide a tight fit with the glazing pockets of the vertical members.

United States Patent 1191 Latson Mar. 26, 1974 FRAME CORNER CONSTRUCTION Primary ExaminerAlfred C. Perham [75] Inventor: Harold LasonNiles Mich Attorney, Agent, or Firm-Mason, Kolehmainen, Rathburn & Wyss [73] Assignee: American Metal Climax, Inc., New

57 ABSTRACT l d: Jan. 8, 1973 There is provided an improved corner construction for [2]] Appl No 321,665 interconnecting construction or frame members of a wall system. The corner construction is particularly 7 useful with, but not limited to, a door structure of the U-S- i type wherein a frame supports a panel of glass or [51 1 Int. Cl. Fl6b 7/18, E040 2/38 other Suitable materiaL The frame is f r d f iof Search cal frame members each face portions con- 52/627, 628; 287/189-36 H nected by a transverse web and defining confronting glazing pockets. Spaced upper and lower rail members References Cited interconnect the vertical members and are each pro- UNITED STATES PATENTS vided with longitudinally extending screw splines. The 2,918,708 12/1959 Sharp et al 52/656 ends of the upper and lower rail members are P 3357.149 12 9 7 Johnston 52 400 X to define tenons so that the screw splines fit within the 3,299,596 1/1967 Neal et a]. 52/656 confronting glazing pockets. Fastener means extend- 3.561301 2/1971 Chiu 52/656 X ing through the transverse webs into the screw splines FOREIGN PATENTS OR APPLICATIONS expand the tenons to provide a tight fit with the glaz- 1.012869 4/1952 France 52/475 mg pockets of the vemcal members M mllll 4 Claims, 4 Drawing Figures FRAME CORNER CONSTRUCTION The present invention relates to a new and improved frame corner construction, and particularly to a corner construction useful in joining frame members of a building wall. The invention is particularly adaptable to, but not limited to, a door structure of the type having extruded frame members supporting a panel such as of glass. Accordingly the invention is herein described in connection with a door frame.

Heretofore difficulty has been experienced in obtaining corner constructions of framing members having a maximum glass or panel size to frame width. Some of the difficulty arises from the requirement that in order to glaze a completed frame assembly, conventional commercial practice requires a shallow and deep glazing pocket to confront each other to provide for installation clearance of the glass. Moreover with reference to doors it is necessary that the door frame members have sufficient strength to withstand the loads imposed upon them. Door frames are particularly critical with regard to the strength of the joints between the stiles and upper and lower rail members. One improved corner joint assembly which overcomes some of the above mentioned difficulties is disclosed and claimed in the copending application filed by Lawrence F. Biebuyck on Dec. 1, 1971, Ser. No. 203,814, and assigned to the same assignee as the present invention. The structure therein disclosed provides for the transfer of torsional loads between the rail assemblies and the vertical stiles without the addition of shear blocks and the like, and further provides for maximum utilization of the stile material so that a door with minimum width stiles may be provided. Although the corner joint therein disclosed is quite satisfactory, close maching and extrusion tolerances are required. Accordingly it would be advantageous to provide a corner joint of the type described above wherein a looser standard of machining and extrusion tolerances would be practical.

Accordingly it is an object of the present invention to provide a new and improved corner construction for a frame member which overcomes the above mentioned difficulties.

Another object of the present invention is the provision of a new and improved door structure.

Still another object of the present invention is the provision of a new and improved corner structure for a door wherein a tight fit is achieved without requiring close machining and extrusion tolerances.

Other objects and advantages of the present invention will become apparent as the following description precedes and the features of novelty which characterize the invention will be pointed out with particularity in the claims annexed to and forming a part of this specification.

In accordance with these and other objects, there is provided an improved corner structure of the type having a frame supporting a panel such as of glass. Each of the vertical frame members has face portions connected by a transverse web and defining confronting shallow and deep glazing pockets. Upper and lower rail assemblies interconnect the vertical frame members and are provided with coped ends defining tenons having screw splines fitting into the confronting glazing pockets. The tenons are split longitudinally of the glazing pockets through the screw splines, and fastener means extending through the transverse webs of the vertical members and into the screw splines expand the tenons to provide a tight fit with the glazing pockets and secure the rail assemblies and the vertical members together. Torsion load between the rail assemblies and the vertical members are reacted through the tenons and against the walls of the glazing pockets.

For a better understanding of the present invention reference may be had to the accompanying drawings wherein:

FIG. 1 is an elevational view of a door incorporating the improved frame corner construction according to the'present invention;

FIG. 2 is a fragmentary elevational sectional view of the door of FIG. 1, taken along line 22 of FIG. 1;

FIG. 3 is a fragmentary plan sectional view of the door of FIG. 1, taken along line 33 of FIG. 1; and

FIG. 4 is a fragmentary perspective exploded view of the door of FIG. 1, illustrating the connection of the rail assemblies with the door stiles.

Refering now to the drawings, there is illustrated a door 10 incorporating the present invention, and illustrated as of the center pivoted, double acting type. The door 10 is formed of spaced vertical stile members 12 and 13 interconnected by upper and lower rail assemblies 15 and 16. The stile members and rail assemblies define a door frame supporting a panel 18 of glass or other suitable material. In the illustrated embodiment the stile member 12 may be referred to as the lock stile, while the stile member 13 may be referred to as the pivot stile.

Refering first to the lock stile member 12, best illustrated in FIGS. 3 and 4, it is formed by an extruded element, such as of aluminum, and provided with relatively heavy face portions 12A, 12B interconnected by a transverse web 12C. The face portions and webs 12A, 12B, 12C together define a shallow glazing pocket 12D and an opposed edge channel 12E.- The confronting edges of the glazing pocket 12D include parts defining gasket'channel 12F for retaining suitable glazing gaskets 19. In the illustrated embodiment the edge channel 12E is of somewhat T-shape, having undercut portions 12G. In addition the edge channel 12E has confronting grooves 12H forslidably receiving a stile cap 20.

The pivot stile member 13 is similar to the lock stile member 12, having the same narrow width if desired, and includes relatively heavy face portions 13A, 13B interconnected by a transverse web 13C. The face portions and webs 13A, 13B, 13C together define a deep glazing pocket 13D and an edge channel 13E. The confronting edges of the glazing pocket 13D are provided with gasket channels 13F supporting suitable glazing gaskets 19. Moreover the confronting edges of the edge channel 13E. are provided with confronting grooves 13H slidably receiving a pivot stile cap 21. If desired studs 23 of nylon or other suitable .material may be threaded through the web 13C against the glazing 18 to prevent creeping of the glazing into the deep-glazing pocket.

It will be appreciated that in a conventional glazing situation the lock stile member 12 is formed with the shallow glazing pocket 12D and has arelatively deep edge channel 12E, while the pivot stile member 13 is formed with a deep glazing pocket 13D and has a shallow edge channel 13E, thus permitting maximum utilization or material and minimum width to the stile members.

The upper rail assembly is formed of a rail member and a face member 26, both of extruded aluminum or other suitable material, and each having parts interfitting to lock the face member 26 to the rail member 25. More specifically, and as best illustrated in FIG. 2, the rail member 25 includes a generally tubular center portion having transverse webs 25A, 25B, and outer face portion 25C, and an inner web 25D. Formed integrally with the inner web is a toe portion 25B and hook portion 25F forming parts interlocking with corresponding parts of the face member. Screw splines 25G are formed with the transverse webs 25A and 258 defining relatively heavy metal portions at the center of the webs. The face member 26 includes a toe portion 26A and a hook portion 26B for camming and interlocking relation with the respective toe and hook portions 25E, 25F of the rail member 25. When assembled the upper rail assembly 15 defines a glazing pocket 27 and an upper open pocket 28 for receiving door closures, operators, and the like.

The lower rail assembly 16 is similar to the upper rail assembly 15, but may differ primarily dimensionally. More specifically the lower rail member 16 includes a rail member 30, FIG. 2, having a generally tubular center portion formed of transverse webs 30A, 308, a face portion 30C and an inner web 30D. A toe portion 30E and a hook portion 30F are provided along the inner web 25D for interlocking relationshipwith a face member 31. Suitable screw splines 30G are provided generally centrally of the rail assembly 16 and define relatively heavy central portions of the transverse webs 30A, 308. The face member 31 also includes a toe portion 31A and a hook portion 318 for interlocking relationship with the toe and hook portions 30E, 30F of the rail member 30. The lower rail assembly 16 also defines a glazing pocket 32 at its upper end, and a downwardly opening pocket 33 at its lower end.

The joint or corner connection of the stile members and rail assemblies are best illustrated in FIG. 4. Refering first to the lock stile and of FIG. 4, the end of the rail assemblies 15 and 16 are coped back so that the relatively heavy portions of the transverse webs defined by the screw splines project in tongue-like manner to form tenons 25H, 30H closely fit and confined within the glazing pocket 12D of the lock stile member 12. Suitable screw fasteners, such as screws 35 are driven into the respective screw splines 25G, 30G through apertures 36 in the stile member 12. The tenons 25H, 30H are each provided with a slit 34 extendong longitudinally relative to the glazing pocket 12D, and extending through the screw splines 25G, 306. The screws 35 are effective to spread the tenons 25H, 30Hso as to eliminate any play in the door joints and to expand the tenons to provide a tight fit with the sides of the respective glazing channels. The stile cap 20 covers the exposed heads of the screws 35.

The connection between the rail assemblies 15 and 16 to the pivot stile member 13 is similar, with the lock ends of the upper and lower rail assemblies 15 and 16 being coped back so that the material in the area of the screw splines 25G, 30G projects in tongue-like manner to form tenons 25H, 30H inserted into the deep glazing pocket 13D of the pivot stile member 13. Suitable screw fasteners, such as screws 37, FIG. 3 are secured within the screw splines 25G, 306 through apertures 38 in the transverse web 13C of the pivot stile member 13. The tenons 25H, 30H on the lock stile end are also provided with slits 34 extending longitudinally of the glazing channel 13D. Thus the screws 37 expand the tenons 25H, 30H at the lock stile end to provide a tight fit between the tenons 25H, 30H and the side walls of the glazing pocket 13D, eliminating play between the members.

The stile cap 21 covers the exposed head of the fasteners 37.

Advantageously the projecting tongue-like portions or tenons of the upper and lower rail assemblies with the vertical slits 34 running through the screw splines 25G, 30G are. effective to spread the tenons to provide a tight fit with the side walls of the glazing pockets 12D, 13D. Play in the corner joints is eliminated and looser machining and extrusion tolerances can be tolerated. Although such play had been found not to be structurally significant, better appearance and alignment of the door and door hardware is maintained with tight corner joints. Moreover a frame or door structure in accordance with the described invention provides for maximum utilization of the frame material so that a door with minimum width stiles is provided. Advantageously the frame or door structure provides pleasing lines and appearance for the architect. Moreover the corner joint of the frame is strong and sturdy, accomplishing transfer of torsional loads between the members directly from the tenons into the side walls of the glazing channels without the addition of shear blocks and the like.

Although the invention has been described by reference to a single embodiment thereof, it will be apparent that numerous other modifications and embodiments may be devised by those skilled in the art which will fall within the true spirit and scope of the present invention.

What is claimed as new and desired to be secured by Letters Patent of the United States is:

1. A corner construction of the type wherein a frame supports a panel such as of glass comprising:

spaced vertical members, each having face portions connected by a transverse web defining confronting glazing pockets:

at least one horizontal assembly interconnecting said members, each of said assemblies including;

a horizontal member having parts thereon defining longitudinally extending screw splines, and including at least one face portion;

the ends of said horizontal assemblies being coped to define tenons with the tenons fitted within the confronting glazing pockets of the vertical members,

said tenons being split vertically through the screw splines, and

fastener means extending through the transverse webs into said screw splines expanding said tenons to provide a tight fit with said glazing pockets and securing said rail assemblies and said vertical member together.

2. A corner construction of the type wherein a frame supports a panel such as of glass comprising:

spaced vertical members, each having face portions connected by a transverse web defining confronting glazing pockets;

spaced rail assemblies interconnecting said vertical members, each of said rail assemblies having a generally tubular portion with parts thereon defining longitudinally extending screw splines;

the ends of said rail assemblies being coped to provide tenons with the ends of the screw splines fitted within the confronting glazing pockets of the vertical members,

said tenons being split vertically through the screw splines, and

fastener means extending through the transverse webs into said screw splinesexpanding said tenons to provide a tight fit'with said glazing pocket and securing said rail assemblies and said vertical members together whereby torsion loads transmitted between said rail assemblies and said vertical members are reacted through said tenons and against the walls of said glazing pockets.

3. A door structure of the type having a frame supporting a panel such as of glass comprising:

spaced vertical door stiles, each having face portions connected by a transverse web defining confronting glazing pockets;

spaced upper and lower rail assemblies interconnecting said stiles, each of said rail assemblies having a rail member having a generally tubular center portion having parts thereon defining longitudinally extending screw splines, and including a face portion;

at least one of said rail members including a face member defining a glass stop and forming a glazing pocket with its face portion;

said one of said rail members and said face member having interlocking parts;

the ends of said rail assemblies being coped to define tenons with the ends of the screw splines fitted within the confronting glazing pockets of the door stiles, and

fastener means extending through the transverse webs into said screw splines expanding said tenons to provide a tight fit with said glazing pocket securing said rail assemblies and said vertical stiles together whereby torsion loads transmitted between said rails and said stiles are reacted through said tongues and against the walls of said glazing pockets.

4. A corner construction of the type wherein a frame supports a panel such as of glass comprising:

fastener means extending through the transverse webs into said screw splines expanding said tenon to provide a tight fit with said glazing pockets and securing said second frame memberand said first frame member together. 

1. A corner construction of the type wherein a frame supports a panel such as of glass comprising: spaced vertical members, each having face portions connected by a transverse web defining confronting glazing pockets: at least one horizontal assembly interconnecting said members, each of said assemblies including; a horizontal member having parts thereon defining longitudinally extending screw splines, and including at least one face portion; the ends of said horizontal assemblies being coped to define tenons with the tenons fitted within the confronting glazing pockets of the vertical members, said tenons being split vertically through the screw splines, and fastener means extending through the transverse webs into said screw splines expanding said tenons to provide a tight fit with said glazing pockets and securing said rail assemblies and said vertical member together.
 2. A corner construction of the type wherein a frame supports a panel such as of glass comprising: spaced vertical members, each having face portions connected by a transverse web defining confronting glazing pockets; spaced rail assemblies interconnecting said vertical members, each of said rail assemblies having a generally tubular portion with parts thereon defining longitudinally extending screw splines; the ends of said rail assemblies being coped to provide tenons with the ends of the screw splines fitted within the confronting glazing pockets of the vertical members, said tenons being split vertically through the screw splines, and fastener means extending through the transverse webs into said screw splines expanding said tenons to provide a tight fit with said glazing pocket and securing said rail assemblies and said vertical members together whereby torsion loads transmitted between said rail assemblies and said vertical members are reacted through said tenons and against the walls of said glazing pockets.
 3. A door structure of the type having a frame supporting a panel such as of glass comprising: spaced vertical door stiles, each having face portions connected by a transverse web defining confronting glazing pockets; spaced upper and lower rail assemblies interconnecting said stiles, each of said rail assemblies having a rail member having a generAlly tubular center portion having parts thereon defining longitudinally extending screw splines, and including a face portion; at least one of said rail members including a face member defining a glass stop and forming a glazing pocket with its face portion; said one of said rail members and said face member having interlocking parts; the ends of said rail assemblies being coped to define tenons with the ends of the screw splines fitted within the confronting glazing pockets of the door stiles, and fastener means extending through the transverse webs into said screw splines expanding said tenons to provide a tight fit with said glazing pocket securing said rail assemblies and said vertical stiles together whereby torsion loads transmitted between said rails and said stiles are reacted through said tongues and against the walls of said glazing pockets.
 4. A corner construction of the type wherein a frame supports a panel such as of glass comprising: a first frame member having face portions connected by a transverse web defining a glazing pocket; a second frame member connected to said first frame member, and having parts thereon defining longitudinally extending screw splines, and including at least one face portion; one end of said second frame member being coped to define a tenon with the tenon fitted within the glazing pocket of the first frame member, said tenon being split longitudinally of said glazing pocket through the screw splines, and fastener means extending through the transverse webs into said screw splines expanding said tenon to provide a tight fit with said glazing pockets and securing said second frame member and said first frame member together. 